Interlocking panel for light weight insulating concrete

ABSTRACT

An interlocking panel configured for lightweight insulating concrete has channels which form a profile that includes transversely protruding anchoring cavities. When the lightweight insulating concrete is poured into the channels and hardens, the concrete interlocks and forms an underside interlocking which resists vertical separation of the concrete from the deck panel.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority of U.S. Provisional PatentApplication No. 61/127,077 filed May 9, 2008, the disclosure of which isincorporated by reference herein.

FIELD

The present disclosure relates to light weight insulating concrete(LWIC), and is more particularly concerned with a deck panel forreceiving LWIC.

The disclosure is directed to an improved deck panel that will result insuperior performance and enhanced lifetime of an LWIC structure, inparticular, a deck or roof installation subjected to windy and adverseenvironmental conditions.

SUMMARY

Briefly stated, a deck panel for receiving a lightweight insulatingconcrete (LWIC) has an upper aerial surface which receives LWIC. Theaerial surface longitudinally extends between opposed first and secondedges. A multitude of transversely spaced parallel channels traverse thepanel and longitudinally extends between the edges. The panel has atransverse profile defined by the geometry of the channels wherein eachchannel has at least one transversely protruding anchoring cavity withan upper and a lower wall. The elongated channels may be configured invarious shapes. One channel has two opposite elongated anchoringcavities, each with an upper and a lower wall. In one embodiment of thedeck panel, channels are symmetric about a central longitudinal planethrough the channel. A channel may have a transverse profile segmenthaving a generally inverted T-shape, a general L-shape, a bulbous shapeor various other shapes configured to provide an interlock between thedeck panel and the LWIC.

A roofing assembly comprises a deck panel having an upper aerial surfacelongitudinally extending between first and second edges. A multitude oftransversely spaced parallel channels traverse the panel. Each channelhas at least one transversely protruding elongated anchoring cavity.Lightweight insulating concrete overlies the aerial surface and extendsinto the channels and forms an integral rigid structure which interlockswith the deck panel.

In one embodiment, each channel has two opposite elongated anchoringcavities, each with an upper and a lower wall, and the hardened LWICextends into the anchoring cavities. In another embodiment, each channelmay be symmetric about a central longitudinal plane through the channel.At least some of the channels have a transverse profile segment whichare configured to provide an interlocking function for the LWIC. In allof the latter embodiments, the LWIC extends into the anchoring cavitiesand is joined with the integral LWIC substrate.

A process for constructing a decking structure comprises providing apanel having an aerial surface for receiving LWIC and which panellongitudinally extends between opposed first and second edges. Amultitude of transversely spaced parallel channels traverse the panel.The panel defines a transverse profile wherein the geometry of eachchannel has at least one longitudinally extending transverselyprotruding anchoring cavity with an upper wall and a lower wall. LWIC ispoured over the panel so that the flowing LWIC substantially fills eachchannel and anchoring cavity and the LWIC forms a relatively flatsurface above the aerial surface of the panel. The LWIC hardens to forma structure which integrally includes the hardened LWIC which isretained in the anchoring cavities.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a standard deck panel profile as knownin the prior art;

FIG. 2 is a side profile, partly in schematic, of the standard deckpanel profile of FIG. 1, showing U or V shaped channels;

FIG. 3 is a perspective view of a deck panel incorporating an improvedinterlocking deck profile;

FIG. 4 is a sectional view of the panel of FIG. 3, and a LWIC overlayinstallation;

FIGS. 5A-5E are enlarged transverse sectional views illustrating variouspossible symmetric panel channel profiles;

FIGS. 6A-6C are enlarged transverse sectional views illustrating variousasymmetric panel channel profiles;

FIGS. 7A-7C are enlarged fragmentary transverse sectional views of deckpanels illustrating multiple channel profiles; and

FIG. 8 is an enlarged sectional and schematic view illustrating aninterlocking relationship of the deck panel and LWIC.

DETAILED DESCRIPTION

As shown in FIGS. 1 and 2, a prior art deck panel 100 provides an aerialsurface 180 with a multitude of truncated U or V-shaped channels 120extending the length of the panel 100. Each channel 120 is relativelyuniformly spaced from and parallel to the other channels. The deckpanels which incorporate a profile of this type are generally made fromsteel or other strong materials. When building a deck, roof or similarstructure, generally the deck panels are rigidly fixed to asuperstructure frame or the like. The channels provide a reinforcingfunction to the panel. Flowing LWIC is poured over the panels, fillingthe crevices of the channels 120. A flat upper surface is formed asindicated by reference numeral 140 in FIG. 2, and the LWIC eventuallyhardens. The hardened LWIC is designated by the numeral 130.

As can be seen, the truncated U or V-shaped channels do not verticallyhold the dried, hardened LWIC in place (i.e., do not provide“mechanical” attachment or a vertical restraint). Thus, the hardenedLWIC layer is susceptible to separation from the panel along interface160, to vertical movement or lifting, and to possible damage in thepresence of high winds. Representative vertical movement and separationvectors are symbolized by arrows F in FIG. 2.

With reference to FIGS. 3 and 4, the disclosed interlocking deck panels10 provide an improved panel profile that will “grip” LWIC concrete,lock it into the decking and prevent vertical separation, thus resultingin superior performance, in particular, under windy and adverseenvironmental conditions.

As indicated in the embodiment depicted in FIGS. 3 and 4, the improvedpanel 10 has an aerial surface 18 traversed by a multitude oflongitudinally extending channels 12 with inverted T-shapedconfigurations. In section, the panel defines a profile defined by thegeometries of the uniformly transversely spaced channels. For purposesof description, the longitudinal direction is designated by arrow L andthe transverse direction by arrow T in FIG. 3. Each inverted T-shapedchannel 12 has opposed transversely protruding cavities 14 extendingoutward from the axial center of each channel 12. Each protruding cavity14 is formed by an upper wall 24 and a lower wall 34 and extendslongitudinally across the panel.

A deck, roof or similar structure can be constructed or installed withthe disclosed panel 10 in a manner similar to the prior art. The panel10 can be rigidly fastened to a frame or similar structure. LWIC ispoured over the panel 10, filling in the channels 12. The LWIC typicallyassumes and/or is distributed to form a flat upper surface, as indicatedby reference numeral 16 in FIG. 4. Furthermore, when employed, thehardened LWIC 20 cooperates with the deck/channel structure to create amechanical catch or interlock along the interface of upper walls 24 andthe portion of hardened LWIC 20 in the anchoring cavities 14. Upperwalls 24 create an elongated separation barrier in the verticaldirection, thus preventing the vertical movement, separation andexternal degradation for which LWIC structures constructed withconventional prior art deck panels may be susceptible.

While the FIG. 3 deck panel 10 embodiment features inverted T-shapedchannels, the interlocking function can be achieved by employingchannels of various shapes-for example L-shaped channel 112A (FIG. 6A)or inverted F-shaped channel 112B (FIG. 6B)—as long as the channels areconfigured with upper walls that create mechanical resistance along theLWIC/panel interface in the vertical direction.

As further illustrated in FIGS. 5A-5E, various profiles of channels 12A,12B, 12C, 12D, 12E which include opposed transversely protrudinganchoring cavities 14A, 14B, 14C, 14D, 14E for interlocking with thelightweight concrete are possible. The channels are dimensioned to allowfor efficient flow of the LWIC into the anchoring cavities.

Although it is generally preferred that the channels be symmetric, forsome panel embodiments, the interlocking anchoring cavities 114A, 114Bmay be asymmetric with respect to a central vertical axis orlongitudinal plane as best illustrated in FIGS. 6A-6B. In addition, itshould be appreciated that the interlocking anchoring cavities 214A,214B may be configured in opposed pairs as illustrated in FIGS. 7A and7B, or channel 112C may be interspersed among the channels 120configured in a manner similar to conventional deck panels asillustrated in FIG. 7C.

As best illustrated in FIG. 8, the interlocking feature is provided by achannel cavity portion which has an upper wall 24. The channel structureallows for the LWIC to enter into the formed cavity and, upon verticallyhardening, interlock the integral LWIC 20 structure with the anchoreddeck panel. The side walls 44 provide a transverse interlock of the LWICstructure, for example, a stable, fixed relationship to the left andright of the central plane P through the channel or any plane parallelto plane P. Accordingly, it will be appreciated that the LWIC will berestrained both vertically and transversely by the interlocking panel10.

For ease of fabrication of the deck panels, which are typically formedfrom steel, the formed channels with the anchoring cavities typicallyextend from one longitudinal edge to the opposing edge. However, forsome embodiments, the channels need not extend the entire longitudinallength of the panel. For most applications, channels with the symmetricprofiles are also preferable since the channels of multiple panels mayinterlock at adjoining edges across the roof substructure. Such asymmetrical relationship facilitates ease of placement and installation.Naturally, a wide variety of channels and spacings both includinganchoring cavities as described and conventional channel form may beprovided across the deck panel.

While preferred embodiments have been set forth for purposes ofillustration, the foregoing description should not be deemed alimitation of the invention herein. Accordingly, various modifications,adaptations and alternatives may occur to one skilled in the art withoutdeparting from the spirit and the scope of the present invention.

1. A deck panel for receiving light weight insulating concrete (LWIC) tocreate a generally flat upper roofing structure, comprising: a panelhaving an upper aerial surface for receiving LWIC and extending betweenopposed first and second edges; and a multitude of transversely spacedparallel channels traversing said panel and longitudinally extendingbetween said edges, said panel defining a transverse profile defined bythe geometry of said channels wherein each channel has at least onetransversely protruding anchoring cavity with an upper and a lower wall.2. The deck panel of claim 1, wherein each channel has two oppositeanchoring cavities, each with an upper wall and a lower wall.
 3. Thedeck panel of claim 2, wherein each channel is symmetric about a centrallongitudinal plane through said channel.
 4. The deck panel of claim 1,wherein a said channel has a transverse profile segment having agenerally inverted T-shape.
 5. The deck panel of claim 1, wherein a saidchannel has a said transverse profile segment having a general L-shape.6. The deck panel of claim 1, wherein a said anchoring cavity has atransverse profile segment having a bulbous shape.
 7. A roofing assemblycomprising: a deck panel having an upper aerial surface andlongitudinally extending between first and second edges, a multitude oftransversely spaced parallel channels traversing said panel andlongitudinally extending between said edges, said panel having atransverse profile defined by the geometry of said channels wherein eachchannel has at least one transversely protruding anchoring cavity withan upper wall and a lower wall; and lightweight insulating concrete(LWIC) overlying said aerial surface and extending into said channelsand forming an integral rigid structure which interlocks with said deckpanel.
 8. The roofing assembly of claim 7, wherein each channel has twoopposite anchoring cavities, each with an upper wall and a lower wall,and said LWIC extends into said anchoring cavities.
 9. The roofingassembly of claim 8, wherein each channel is symmetric about a centrallongitudinal plane through said channel.
 10. The roofing assembly claim7, wherein a said channel has a transverse profile segment having agenerally inverted T-shape.
 11. The roofing assembly claim 7, wherein asaid channel has a said transverse profile segment having a generalL-shape.
 12. The deck panel of claim 7, wherein a said anchoring cavityhas a transverse profile segment having a bulbous shape.
 13. A processfor constructing a decking structure comprising: providing a panelhaving an aerial surface for receiving LWIC and longitudinally extendingbetween first and second edges, and a multitude of transversely spacedparallel channels traversing said panel and longitudinally extendingbetween said edges, said panel having a transverse profile defined bythe geometry of said channels wherein at least one channel has at leastone longitudinally extending, transversely protruding anchoring cavitywith an upper and a lower wall; pouring flowing light weight insulatingconcrete LWIC over the panel so that the flowing LWIC substantiallyfills each channel and protrusion and forms a relatively flat surfacealong the aerial surface of the panel; and allowing the LWIC to hardenin a said anchoring cavity to form an integral structure whichinterlocks with said panel.